Hyundai Atos Shop Manual

General Information

GENERAL

EATC0100

HOW TO USE THIS MANUAL

This manual is divided into 21 sections. The first page of each section is marked with a black tab at the edge of the

page. You can quickly find the first page of each section without looking through the whole table of contents.

Each section includes the essential removal, installation, adjustment and maintenance procedures for servicing all body

styles. This information is correct at the time of publication.

An INDEX is provided on the first page of each section to guide you to the appropriate item.

TROUBLESHOOTING tables are included for each system to help you diagnose the system problem and find the

cause. The repair for each possible cause is referred to in the remedy column to lead you to the solution quickly.

DEFINITION OF TERMS

Standard Value (Service standard)

Indicates the value used when a part or assembled item should be inspected, or the value to which a part or assembled

item should be adjusted after reinstallation. It is given by a tolerance.

Service Limit

Indicates the maximum or minimum value that a part or assembled item must meet when inspected. It is a value

established beyond the standard value.

NOTE, WARNING , CAUTION, ABBREVIATION

NOTE

Information needed in reference to a repair service.

CAUTION

Information about an activity that could cause damage to the vehicle.

WARNING

Information about an activity that could cause injury or damage to the driver, occupants or repairman.

ABBREVIATIONS

SOHC: Single Over Head Camshaft

VEHICLE IDENTIFICATION NUMBER LOCATION

The vehicle identification number (VIN) is located on the top of the fire wall.

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number consists of 17 digits.

1. W.I.C. (World manufacturer's Identification Code)

KMH - Hyundai Motor Company, Korea

2. Vehicle Line

A : ATOS

3. Model & Series

F : Standard (L)

G : Deluxe (GL)

H : Super deluxe (GLS)

4. Body Type

5 : Sedan 5DR

5. Restraint system

0 - Both sides (None)

1 - Both sides (A/Belt)

2 - Both sides (P/Belt)

3 - Driver side : A/ Belt + A/Bag, Passenger side : P/Belt

4 - A/ Belt + A/ Bag (Driver side + Passenger side)

5 - Depowered A/Bag

NOTE

A/Belt : Active belt

P/Belt : Passive belt

A/Bag : Air bag

6. Engine type

G : G 1.0 S

7. Check digit or others

P : LHD (Left Hand Driver)

R : RHD (Right Hand Driver0

8. Production year

Y - 2000 Model Year, 2 - 2002 Model Year

1 - 2001 Model Year, 3 - 2003 Model Year

9. Production plant

U - Ulsan (Korea)

10. Vehicle production sequence number

000001 - 999999

ENGINE IDENTIFICATION NUMBER LOCATION

The engine identification number is stamped on the right front side of the top edge of the cylinder block.

DESCRIPTION OF ENGINE IDENTIFICATION NUMBER

The engine identification number consists of 11 digits.

1. Engine fuel

G - Gasoline

2. Engine range

4 - In line 4 cycle 4 cylinder

3. Engine development order

H : Epsilon engine

4. Engine capacity

C : 999cc

5. Production year

X - 1999

Y - 2000

1 - 2001

2 - 2002

6. Engine production sequence number

000001 - 999999

PROTECTION OF THE VEHICLE

Always be sure to cover fenders, seats, and floor areas before starting work.

CAUTION

The support rod must be inserted into the hole near the edge of the hood whenever you inspect the engine

compartment to prevent the hood from falling and causing passible injury.

Make sure that the support rod has been released prior to closing the hood. Always check to be sure the hood is

firml

y

latched before drivin

g

the vehicle.

A WORD ABOUT SAFETY

The following precautions must be followed when jacking up the vehicle.

1. Block the wheels.

2. Place a jack under the specified jacking point.

3. Support the vehicle with safety stands (jack stands) Refer to the page GI-10.

4. Start the engine when engine compartment is clear.

PREPARATION OF TOOLS AND MEASURING EQUIPMENT

Be sure that all necessary tools and measuring equipment are available before starting work.

SPECIAL TOOLS

Use special tools when they are required.

REMOVAL OF PARTS

First find the cause of the problem and then determine whether removal or disassembly is required before starting the

job.

DISASSEMBLY

If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be disassembled in

a way that will not affect their performance or external appearance.

1. Inspection of parts

Each part, when removed, should be carefully inspected for malfunction, deformation, damage, and other

problems.

2. Arrangement of parts

All disassembled parts should be carefully arranged for effective reassembly.

Be sure to separate and correctly identify the parts to be replaced from those that will be used again.

3. Cleaning parts for reuse

All parts to be used again should be carefully and thoroughly cleaned by an appropriate method.

PARTS

When replacing parts, use HYUNDAI genuine parts.

REPLACEMENT

Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts.

If removed, the following parts should always be replaced with new ones.

1. Oil seals

2. Gaskets

3. O-rings

4. Lock washers

5. Cotter pins (split pins)

6. Plastic nuts

Depending on their location.

1. Sealant should be applied to gaskets.

2. Oil should be applied to the moving components of parts.

3. Specified oil or grease should be applied to the prescribed locations (oil seals, etc.) before assembly.

ADJUSTMENT

Use gauges and testers to adjust correctly the parts to standard values correctly.

ELECTRICAL SYSTEM

1. Be sure to disconnect the battery cable from the negative (-) terminal of the battery.

2. Never pull on the wires when disconnecting connectors.

3. Locking connectors will click when the connector is secure.

4. Handle sensors and relays carefully. Be careful not to drop them or hit them against other parts.

RUBBER PARTS AND TUBES

Always prevent gasoline or oil from touching rubber parts or tubing.

MEASURING BODY DIMENSIONS

1. Basically, all measurements in this manual are taken with a tracking gauge.

2. When a measuring tape is used, check to be sure there is no elongation, twisting or bending

3. For measuring dimensions, both projected dimensions and actual-measurement dimensions are used in this

manual.

DIMENSIONS PROJECTED

1. These are the dimensions measured when the measurement points are projected from the vehicle's surface,

and are the reference dimensions used for body alterations.

2. If the length of the tracking gauge probes is adjustable, measure it by lengthening one of two probes as long as

the different value in height of the two surfaces.

MEASURING ACTUAL DIMENSIONS

1. These dimensions indicate the actual linear distance between measurement points, and are used as the

reference dimensions when a tracking gauge is used for measurement.

2. First adjust both probes to the same length (A=A') before measurement.

NOTE

Check the probes and gauge itself to make sure there is no free play.

MEASUREMENT POINT

Measurements should be taken at the center of the hole.

CHECKING CABLES AND WIRES

1. Check the terminal for tightness.

2. Check terminals and wires for corrosion from battery electrolyte, etc.

3. Check terminals and wires for open circuits.

4. Check wire insulation and coating for damage, cracks and degrading.

5. Check the conductive parts of terminals for contact with other metallic parts (vehicle body and other parts).

6. Check grounded parts to verify that there is complete continuity between their attaching bolt(s) and the vehicle's

body.

7. Check for incorrect wiring.

8. Check that the wiring is so clamped to prevent contact with sharp corners of the vehicle body, etc. or hot parts

(exhaust manifold, etc.)

9. Check that the wiring is clamped firmly to provide enough clearance from the fan pulley, fan belt and other

rotating or moving parts.

10. Check that the wiring has a little space so that it can vibrate between fixed and moving parts such as the vehicle

body and the engine.

CHECKING FUSES

A blade type fuse has test taps provided to allow checking the fuse itself without removing it from the fuse block. The

fuse is good if the test lamp lights up when one lead is connected to the test taps (one at a time) and the other lead is

grounded. (Turn the ignition switch so that the fuse circuit becomes operative.)

SERVICING THE ELECTRICAL SYSTEM

1. Prior to servicing the electrical system, be sure to turn off the ignition switch and disconnect the battery ground

cable.

NOTE

In the course of MFI or ELC system diagnosis, when the battery cable is removed, any diagnostic trouble

code retained by the computer will be cleared. Therefore, if necessary, read the diagnostic codes before

removing the battery cable.

2.

3. Attach the wiring harnesses with clamps so that there is no slack. However, for any harness which passes the

engine or other vibrating parts of the vehicle, allow some slack within a range that does not allow the engine

vibrations to cause the harness to come into contact with any of the surrounding parts, and then secure the

harness by using a clamp.

4. If any section of a wiring harness interferes with the edge of a part, or a corner, wrap the section of the harness

with tape or something similar in order to protect it from damage.

5. When installing any parts, be careful not to pinch or damage any of the wiring harnesses.

6. Never throw relays, sensors or electrical parts, or expose them to strong shock.

7. The electronic parts used in the computer, relays, etc. are readily damaged by heat. If there is a need for

service operations that may cause the temperature to exceed 80°C (176°F), remove the electronic parts

beforehand.

8. Loose connectors cause problems. Make sure that the connectors are always securely fastened.

9. When disconnecting a connector, be sure to grip only the connector, not the wires.

10. Disconnect connectors which have catches by pressing in the direction of the arrows shown the illustration.

11. Connect connectors which have catches by inserting the connectors until they make a clicking sound.

12. When using a circuit tester to check continuity or voltage on connector terminals, insert the test probe into the

harness side. If the connector is a sealed connector, insert the test probe through the hole in the rubber cap

until it contacts the terminal, being careful not to damage the insulation of the wires.

13. To avoid overloading the wiring, take the electrical current load of the optional equipment into consideration, and

determine the appropriate wire size.

Nominal size SAE gauge No.

Permissible current

In engine compartment Other areas

0.3 mm² AWG 22 - 5A

0.5 mm² AWG20 7A 13A

0.85 mm² AWG18 9A 17A

1.25 mm² AWG16 12A 22A

2.0 mm² AWG14 16A 30A

3.0 mm² AWG12 21A 40A

5.0 mm² AWG10 31A 54A

PRECAUTIONS FOR CATALYTIC CONVERTER

CAUTION

If a large amount of unburned gasoline flows into the converter, it may overheat and create a fire hazard. To

prevent this, observe the following precautions and explain them to your customer.

1. Use only unleaded gasoline.

2. Do not run the engine while the car is at rest for a long time. Avoid running the engine at fast idle for more than

10 minutes and at idle speed for more than 20 minutes.

3. Avoid spark-jump tests. Do spark-jumps only when absolutely necessary. Perform this test as rapidly as

possible and, while testing, never race the engine.

4. Do not measure engine compression for an extended time. Engine compression tests must be made as rapidly

as possible.

5. Do not run the engine when the fuel tank is nearly empty. This may cause the engine to misfire and create an

extra load on the converter.

6. Avoid coasting with the ignition turned off and during prolonged braking.

7. Do not dispose of a used catalytic converter together with parts contaminated with gasoline or oil.

SRS SYSTEM COMPONENTS INFORMATION

CUSTOMER CAUTIONS

Failure to carry out service operations in the correct sequence could cause the airbag system to be deployed

unexpectedly during servicing, and a serious accident to occur. Further, if there is a mistake in servicing the airbag

system, it is possible that the airbag may fail to operate when required. Before servicing (including removal or

installation of parts, inspection or replacement), be sure to read the following items carefully, then follow the correct

procedures described in the repair manual.

1. Work must be started approx. 30 seconds or longer after the ignition switch is turned to the LOCK position and

the negative (-) battery cable is disconnected. (The airbag system is equipped with a back-up power source. If

work is started within 30 seconds when disconnecting the negative (-) battery cable of the battery, the airbag

may be operative.) When the negative (-) terminal cable is disconnected from the battery, the clock and audio

systems memories will be erased. Before starting work, record the setting of the audio memory system. When

work is finished, reset the audio system as before and adjust the clock.

2. Malfunction symptoms of the airbag system are difficult to confirm, so diagnostic codes become the most

important source of information when troubleshooting. When troubleshooting the airbag system, always read the

diagnostic trouble codes before disconnecting the battery.

3. Never use airbag parts from another vehicle. When replacing parts, replace them with new parts.

4. Never attempt to disassemble and repair the airbag modules, SRSCM, clock spring and Air-bag wiring harness

in order to reuse it.

5. If the SRSCM or air-bag module have been dropped, or if there are cracks, dents or other defects in the case,

bracket or connector, replace them with new ones.

6. After work on the airbag system is completed, reset the SRS SRI.

CAUTION

1. Never use a jack beneath the lateral rod or rear suspension assembly.

2. In order to prevent scarring the sub frame, place a piece of cloth on the jack's contact surface (to prevent

corrosion caused by damage to the coating).

3. Never support a vehicle with only a jack. Always use safety stands.

4. Do not attempt to raise one entire side of the vehicle by placing a jack midway between the front and rear

wheels. To do so could result in permanent damage to the body.

TIGHTENING TORQUE

TABLE OF STANDARD

PARTS

Pitch (mm)

Torque Nm (kg.cm, Ib.ft)

Head Mark 4 Head Mark 7

Bolt nominal diameter

(mm)

M5 0.8 3-4 (30-40, 2.2-2.9) 5-6 (50-60, 3.6-4.3)

M6 1.0 5-6

(

50-60, 3.6-4.3

)

9-11

(

90-110, 6.5-8.0

)

M8 1.25 12-15 (120-150, 9-11) 20-25 (200-250, 14.5-18.0)

M10 1.25 25-30 (250-300, 18-22) 30-50 (300-500, 22-36)

M12 1.25 35-45 (350-450, 25-33) 60-80 (600-800, 43-58)

M14 1.5 75-85(750-850,54-61) 120-140(1,200-1,400,85-100)

M16 1.5 110-130(1,100-1,300,80-94) 180-210(1,800-2,100, 130-150)

M18 1.5 160-180(1,600-1,800, 116-130) 260-300(2,600-3,000, 190-215)

M20 1.5 220-250 (2,200-2,500, 160-180) 360-420 (3,600-4,200,260-300)

M22 1.5 290-330 (2,900-3,300, 210-240) 480-550 (4,800-5,500,350-400)

M24 1.5 360-420 (3,600-4,200, 260-300) 610-700 (6,100-7,000, 440-505)

NOTE

1. The torques shown in the table are standard values under the following conditions:

o Nuts and bolts are made of galvanized steel bar.

o Galvanized plain steel washers are inserted.

o All nuts, bolts, and plain washers are dry.

2. The torques shown in the table are not applicable:

o When spring washers, toothed washers and the like are inserted.

o If plastic parts are fastened.

o If self-tapping screws or self-locking nuts are used.

o If threads and surfaces are coated with oil.

3. If you reduce the torques in the table to the percentage indicated below, under the following conditions, if

will be the standard value.

o If spring washers are used. : 85%

o If threads and bearing surfaces are stained with oil. : 85%

Engine Mechanical

GENERAL

ECTC0010

EPSILON ENGINE APPEARANCE

SPECIFICATIONS ECTC0020

Description Specification Limit

General

Type

Number of cylinders

Bore

Stroke

Total displacement

Compression ratio

Firing order

Idle R.P.M

Ignition timing at idling speed

In-line 12 valve SOHC

4

1.0L Eng.

66.0 mm (2.60 in.)

73.0 mm (2.87 in.)

999C

9.7

1-3-4-2

900±100

BTDC 5°±2°/900 rpm

Valve timing

Intake valve

Opens (BTDC)

Closes (ABDC)

Exhaust valve

Opens (BTDC)

Closes (ABDC)

5°

35°

43°

5°

Cylinder head

Flatness of gasket surface

Flatness of manifold mounting surface

Oversize rework dimension of valve seat hole

Intake

0.3 mm (0.012 in.) O.S.

0.6 mm (0.024 in.) O.S.

Exhaust

0.3 mm (0.012 in.) O.S.

0.6 mm (0.024 in.) O.S.

Oversize rework dimensions of valve guide

hole (both intake and exhaust)

0.05 mm (0.002 in.) O.S.

0.25 mm (0.010 in.) O.S.

0.50 mm (0.020 in.) O.S.

Max. 0.05 mm (0.002 in.)

Max. 0.15 mm (0.0059 in.)

24.3 - 24.321 mm (0.956 - 0.957 in.)

24.6 - 24.621 mm (0.968 - 0.969 in.)

29.3 - 29.321 mm (1.154 - 1.154 in.)

29.6 - 29.621 mm (1.165 - 1.166 in.)

10.05 - 10.068 mm (0.395-0.396 in.)

10.25 - 10.268 mm (0.403-0.404 in.)

10.50 - 10.518 mm (0.413-0.414 in.)

0.1 mm (0.0039 in.)

0.3 mm (0.0118 in.)

Camshaft

Cam height

Intake

Exhaust

Journal O.D

Bearing oil clearance

End play

34.8729 mm (1.3729 in.)

35.1258 mm (1.3842 in.)

Ø41 (-0.045, -0.060) mm (1.181 in.)

0.045 - 0.085 mm (0.0018 - 0.1016 in.)

0.070 - 0.190 mm (0.003 - 0.0075 in.)

34.7729mm (1.3690in.)

35.0258mm (1.3790in.)

Valve

Stem O.D.

Intake

Exhaust

Face angle

Thickness of valve head (Margin)

Intake

Exhaust

Valve stem to valve guide clearance

Intake

Exhaust

5.48 - 5.465 mm (0.216 - 0.215 in.)

5.45 - 5.43 mm (0.2146 - 0.2150 in.)

45° - 45.5°

0.8 mm (0.031 in.)

1.2 mm (0.047 in.)

0.020 - 0.047 mm (0.0007 - 0.0019 in.)

0.050 - 0.082 mm (0.0020 - 0.0032 in.)

0.5 mm (0.078 in.)

0.9 mm (0.035 in.)

0.1 mm (0.004 in.)

0.15 mm (0.006 in.)

Valve guide

Installed dimension O.D.

Intake

Exhaust

Service size

10.05 - 10.06 mm (0.3957-0.3961 in.)

0.05, 0.25, 0.50 mm

(0.002, 0.010, 0.020 in.) oversize

Valve seat insert

Width of seat contact

Intake

Exhaust

Seat angle

Oversize

0.9 - 1.3 mm (0.035 - 0.051 in.)

44° (+0/-30)

0.3 mm, 0.6 mm (0.012 in., 0.024 in.)

Valve spring

Free length

Load

Installed height

Squareness

40.50 mm (1.594 in.)

15.6±0.9 kg/32.0 mm at height

33.3±1.8 kg/24.5 mm at height

22.1 mm (0.870 in.)

1.5°or less

Cylinder block

Cylinder bore

Out-of-roundness and taper of cylinder bore

Clearance with piston

66.0 - 66.03 mm (2.599 - 2.600 in.)

Less than 0.01 mm (0.0004 in.)

0.02 -0.04 mm (0.0008 - 0.0016 in.)

Piston

O.D.

Service size

65.97 - 66.0 mm (2.5976 - 2.5988 in.)

0.25, 0.50, 0.75, 1.00 mm

(0.010, 0.020, 0.030, 0.039 in.) oversize

Piston ring

Side clearance

No. 1.

No. 2.

End gap

No. 1.

No. 2.

Oil ring side rail

Service size

0.03 - 0.07 mm (0.001 - 0.003 in.)

0.02 - 0.06 mm (0.0007 - 0.0024 in.)

0.15 - 0.30 mm (0.006 - 0.012 in.)

25 - 0.40 mm (0.010 - 0.016 in.)

0.20 - 0.70 mm (0.008 - 0.028 in.)

0.25, 0.50, 0.75, 1.00 mm

(0.010, 0.020, 0.030, 0.039 in.)

0.1 mm (0.004 in.)

1 mm (0.039 in.)

Connecting rod

Bend

Twist

Connecting rod big end to crankshaft side

clearance

0.05 mm (0.002 in.) or less

0.1 mm (0.004 in.) or less

0.10 - 0.25 mm (0.004 - 0.010 in.)

0.4 mm (0.016 in.)

Connecting rod bearing

Oil clearance

Undersize

0.012 - 0.041 mm (0.0004 - 0.0016 in.)

0.25 - 0.50 mm (10.01 - 0.02 in.)

Crankshaft

Pin O.D.

Journal O.D.

Bend

End play

38 mm (1.496 in.)

42 mm (1.654 in.)

0.03 mm or less

0.25 mm (0.002 - 0.0098 in.)

Crankshaft bearing

Oil clearance

No. 1, 2,3,4,5

Undersize rework dimension of pin

0.25 mm (0.010 in.)

0.50 mm (0.020 in.)

Undersized rework dimension of journal

0.25 mm (0.010 in.)

0.50 mm (0.020 in.)

0.020-0.038 mm (0.0008-0.0015 in.)

37.735-37.75 mm (1.4856 - 1.4862 in.)

37.485-37.50 mm (1.4758 - 1.4764 in.)

41.735-41.75 mm (1.643 - 1.6437 in.)

41.485-41.50 mm (1.6333 - 1.6229 in.)

Flywheel

Run-out

0.1 mm (0.004 in.)

0.13 mm (0.005 in.)

Oil pump

Clearance between outer circumference and

front case

Clearance between roter axial side and front

case

Tip clearance between outer and inner roter

0.10 - 0.18 mm (0.0039 - 0.0071 in.)

0.04 - 0.095 mm (0.0016 - 0.0037 in.)

0.060 - 0.018 mm (0.0024 - 0.0007 in.)

Engine oil pressure

At engine idle speed

Relief spring

Free height

Load

147 KPa (1.5 kg/cm², 21.33 psi)

38.6 mm (1.5197 in.)

3.65 ± 0.4 kg at 33.0 mm

(8.05 ± 0.88 lb. at 1.2992 in.)

Cooling method Water-cooled, Pressurized, Forced

circulation with electrical fan

Coolant

Quantity

6 lit (7 U.S. quarts. 6.9 imperial. quarts.)

Radiator

Type

Performance

Pressurized corrugated fin type

27,000 Kcal/h

Radiator cap

Main valve opening pressure

Vacuum valve opening pressure

73.6-1.3 kPa (10.65-14.91 psi, 0.75-1.05

kg.cm²)

4.90 kPa (0.71 psi, 0.05 kg/cm²) or less

Coolant pump Centrifugal type impeller

Thermostat

Type

Valve opening temperature

Full-opening temperature

Wax pellet type with jiggle valve

82° (180°F)

95°C (203°F)

Drive belt

Type

V-ribbed belt

Engine coolant temperature sender

Type

Resistance

Thermistor type

123.8-168.8Ω at 60°C (140°F)

23.5-29.5Ω at 115°C (239°F)

Thermo switch (on radiator)

Operating temperature

OFF→ON

ON

→OFF

85±3°C (185±5.4°F)

78°C (172°F) or more

Engine coolant temperature sensor

Type

Resistance

Heat-sensitive thermistor type

2.13-1.61 kΩ at 20°C (68°F)

258-322 Ω at 80°C (122°F) or more

Switching temperature Switches “ON” at 50°C (122°F) or move

Automatic transaxle oil cooler

Performance

1,000 Kcal/h

Standard value

Coolant concentration

40%

Air cleaner

Type

Element

Dry type

Panellett type

Exhaust pipe

Muffler

Suspension system

Expansion resonance type

Rubber hangers

TIGHTENING TORQUE ECTC0030

Item Nm kg.cm lb·ft

Cylinder Block

Front roll stopper bracket bolt

(

M10

)

45-55

450-550

33-41

Page is loading ...

Hyundai Atos Shop Manual

Hyundai Atos Shop Manual

Related papers

Other documents